Development and Engineering of a Synthetic Gas Cooler Concept … · 2018. 4. 17. · 5th International Freiberg Conference on IGCC & XtL Technologies Conference 21. May to 24. May

Energy Sector© Siemens AG 2011© Siemens AG 2012. All rights reserved.

5th International Freiberg Conference on IGCC & XtL Technologies

Conference 21. May to 24. May 2012,

Leipzig - Germany

Development and Engineering of a Synthetic Gas Cooler Concept

Integrated in a Siemens Gasifier Design

Ulrich Guenther (presenter) Siemens Fuel Gasification Technology GmbH & Co. KG

Energy Sector© Siemens AG 2011© Siemens AG 2012. All rights reserved.

“A technical invention obtains importance and significance, if

the technology itself is advanced so far that the

invention has become feasible and a general need”

Werner von Siemens 1892

21. May 2012, FreibergPage 3© Siemens AG 2011

Energy Sector

Agenda

Siemens Strategy and Place of GasificationSiemens Strategy and Place of Gasification

Main Project Landscape SFGTMain Project Landscape SFGT

Application Fields and Business ModelApplication Fields and Business Model

TEIMAB Project TEIMAB Project OverviewOverview

Conclusion and Conclusion and Future OpportunitiesFuture Opportunities


Energy Sector

The planned structure as of October 1, 2011

Industry Infrastructure & Cities Energy Healthcare

■ Industry Automation■ Drive Technologies■ Service

■ Power Distribution/Smart Grid Applications

■ Building Technologies■ Mobility

■ Fossil Power Generation

Siemens Fuel Gasification■ Renewable Energy■ Power Transmission■ Oil & Gas■ Energy Service

■ Imaging & Therapy■ Clinical Products■ Diagnostics■ Customer Solutions

Industry Solutions ■ Osram Power Distribution

OsramBuilding Technologies

Mobility

Siemens AG – Strategy Reorganization in order to better serve our customers

New Sector


Energy Sector

Siemens Energy Sector –Newly focused on the markets of tomorrow

Solar & Hydro

Power Transmission

Oil & Gas Fossil PowerGeneration

Wind Power

Energy Service

Energy products and solutions – in 6 Divisions

Siemens FuelGasification


Energy Sector

9 SFG-500 gasifiers shipped / installed for 3 projects8 SFG-500 gasifier under manufacturing and additional 22 SFG-500 (CtL) under contract

SIEMENS SFGT Main Project Landscape

Siemens OfficesOperating UnitsCurrent ProjectsTechnology Selected

HQ FreibergTest Facility

JinChengAmmonia

Shenhua Ningxia Coal Group

(NCPP)Polypropylene

COD 2011

Secure Energy Transportation Fuel

Capital PowerPower

AEC Ammonia

Summit PowerPower + Ammonia

GSP China Beijing

VresovaPower

COD 2008

Schwarze PumpeSyngas for Chemical Industry

1984 - 2007

Tenaska Inc. SNG/Power

Ukraine ClientSyngas for

Chemical Industry

Syngas Ltd.Transportation Fuel

Orlando

Japanese ClientChemicals

Shanghai

CPI YinanSNG


Energy Sector

China NCPP Project Site Impression

Gasifier building

Slag formation on cooling screen

Entire gasification unit with gasifier building CO shift and black water treatment plant


Energy Sector

Siemens Fuel Gasification Technology: Application Fields - Cooling screen reactor

HighlightsSFG Gasifier

o ve rflo wW a te r

G a s o u tle t

C o o lin g ja c ke t

O xy g e n , s te a mF u e l

P re ssu r. w a te ro u tle t

B u rn e r

G ra n u la te d s la g

C o o lin g sc re e n

P re s su r. w a te r

Q u e n chw a te r

in le t

Multi-fuel gasifier (standard 500 MWth) accepts a wide variety of fuels with ash content of > 3%compact size compared to other gasifiersAbility to supply syngas at higher pressuresNo ash to handle (only solid slag as saleable by-product)

Dry feeding (entrained flow)high efficiencyhigh carbon conversion rate (> 98%)

Cooling screenshort start-up / shut-down low maintenance (lifetime > 10 years)high availability

Full quenchsimple and reliableideal for CO sour shiftHigh syngas quality (free of tar)Minimal efforts in gas cleaning


Energy Sector

New Application Fields and Business Model with HRSG

FT Synthesis

Methanol Synthesis

Ammonia Production

Syngas(CO + H2)

Power

Transportationfuels

Methanol

Ammonia / Fertilizer

SNG

Coal

Lignite

Power Island

Chemicals and Synfuel Production

Fuel Gas Island Applications

Fuel preparation

Petcoke

Air Separation Unit

Gasifier Island

Gasifier

CO Shift(optional)

Sulfur Removal

CO2 Removal(optional)

Refinery residues

Biomass

Siemens Basic Engineering & Design Siemens Supply of Key Equipment Siemens EPC

Hydrogen

SNG Production

Third Party Scope for FEED and EPC

Gas turbineSteam turbine

Generator

Combined Cycle

Steam Drum and Steam Circuit incl.

Pumps

Feed Water

Steam

HRSG - Heat Recovery Steam Generator


Energy Sector

Project Organization ChartGermany Government ( BMWI / PTJ )

funded R&D Project COORETEC


Energy Sector

TEIMAB Project Time Schedule


Energy Sector

Step 1: Variation of Main Tech. Sys. Gasification Island

L

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12

K

J

I

H

G

F

E

D

C

B

A

L

K

J

I

H

G

F

E

D

C

B

A

13 14 15 16

Distribution and reproduction of this document, use and disclosure of the contents are prohibited, unless specifically authorized. Contraventions will be indemnified. All patent rights on registered designs are reserved.

UNID

Checked Date: Name: Approved Date: Name: Scale Drawingdimension

Drawn Date: Name: Prepared Date: Name: Rev.Index

Description Drawing Number

Project Project Number

Customer SIEMENSFuel Gasification

Technology GmbH

2009-02-11

2009-02-11

2009-02-11

2009-02-11

T. Fleischer

R. Schumann

T. Fleischer

C. Reuther

P01

- -

F&E TEIMAB

SIEMENS AG

Index Revisions Drawn Checked Approved Date

P01 Preliminary T. Fleischer R. Schumann C. Reuther 2009-02-11

PRELIMINARY12

1 OSBL2 ISBL (SIEMENS)

Notes:- not all minor equipment is shown on the PFDs

Battery Limit Gasifier IslandCONFIDENTIAL

PFD -Variante A

0009WC UT290-???

Cooling Water2039

0008WCR

290-????

Cooling Water2039

0002WBM UT290-????

0001WBL UT290-????

0014SL Header280-????

0005NH UT

280-????

0006GX UT

280-????

0018BW Flash1261-0001

0017 GR Gas Scrubber

251-0001

0019 WS Slag Discharge

241-???

0007CD Feeding

221-????

13-03

13-05

13-04

13-02

FC

0004FG UT

290-????FC

BCC Fine FilterF-23101

BCC PumpP-23101 A/B

13-19

PC

13-18

LC

CJ PumpP-23104 A,B

LCE

Quench Water FilterF-23103 A/B

0011CG K/O Drum

251-0001

0010WQ Venturi251-0001

Quench Water PumpP-23103 A/B/C

LCD

Gasifier Line 1PROCESS FLOW DIAGRAM

13-25

13-10

13-26

0013SL Heater280-????

FC

GasifierR-23101

0016WBH ????

?????

0015SH ?????????

2310-001

0012WK ????290-???? 2310-015

2310-014

2310-013

Quench Water VesselD-23103

2310-016

2310-017

2310-001

Emergency Quench Water VesselD-23105

CJ CoolerE-23104

CJ DrumD-23104

231 - 0001

2310-030

2310-032

2310-033

0003SI UT

290-????

BURNERB-23101

BCC CoolerE-23101

BCC DrumD-23101

CSC PumpP-23102 A,B/C

CSC Steam DrumE-23102

CSC DrumD-23102

L

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12

K

J

I

H

G

F

E

D

C

B

A

L

K

J

I

H

G

F

E

D

C

B

A

13 14 15 16

Distribution and reproduction of this document , use and disclosure of the contents are prohibited , unless specifically authorized . Contraventions will be indemnified. All patent rights on registered designs are reserved .

UNID

Checked Date: Name: Approved Date: Name: Scale Drawingdimension

Drawn Date: Name: Prepared Date: Name: Rev.Index

Description Drawing Number

Project Project Number

Customer SIEMENSFuel Gasification

Technology GmbH

2009-02-11

2009-02-11

2009-02-11

2009-02-11

T. Fleischer

R. Schumann

T. Fleischer

C. Reuther

P01

- -

F&E TEIMAB

SIEMENS AG

Index Revisions Drawn Checked Approved Date

P01 Preliminary T.Fleischer R.Schumann C.Reuther 2009-02-11

PRELIMINARY12

1 OSBL2 ISBL (SIEMENS)

Notes:- not all minor equipment is shown on the PFDs

Battery Limit Gasifier IslandCONFIDENTIAL

PFD -Variante B

Cooling Water????

Cooling Water????

Cooling Water????

Black Water fromGasifier

231-0001

Black Water toBlack Water Treatment

270-0003

Vent Gas toBWT Plant270-0003

Flash Condensate toBWT Plant270-0003

Black Water toBlack Water Treatment

270-0003

Flash System Line 1PROCESS FLOW DIAGRAM

425 861 477

261 - 0001

Cooling Water2039

Cooling Water2039

Vent Gas toBlack Water Treatment

270-0003

Cooling Water????

Wash Water from Gas Cleaning

251-0001

E

LC

LC

PC

Flash 1D-2610101

Flash 2D-2610102

Flash Cooler DrumD-2610202

E

PU Flash ValvesPU-2610001

Flash Bypass DrumD-2610402

Flash PumpP-2610103A/B

Flash Bypass CoolerE-2610401A/BFlash Bypass Cooler

E-2610401A/B

2610-008

2610-009

2610-016

2610-007

Flash Cooler 1E-2610201

2610-005

2610-006

2610-013

Vacuum PumpC-2610303A/B

Separator DrumVacuum PumpD-2610304A/B

Cooler Vacuum PumpE-2610305A/B

2610-010

2610-014

Flash Cooler 2E-2610301

2600-009

2600-008

2600-007


2610-012 2610-015

2610-011

2600-015

2600-010

2610-002

2610-003

2610-004

2610-001

2610-017


Comparison of ProcessModells:

Variant A:

Variant B:


Energy Sector

Step 2 Thermodynamic Investigation

IGCC Performance Data for Heat Recovery Systems (Variants Example)

Results:

• generation of HP steam it’s

a large efficiency advantage

in relation to IP steam

generation

• efficiency improvement

between 1.4 and max. 1.9 %

points for the variants

• comparing the two cooler

types, the radiant cooler

shows a slight efficiency

advantage

Therefore, the thermodynamic results did not lead to a clear decision criterion for concept selection.


Energy Sector

HRSG Step 3 Comparison of Design Concepts

Investigation:

• Process integration

• Additional CAPEX

and OPEX

3D Detail studies


Energy Sector

Step 4 Technical Assessment and Decision

Development criterias technical evaluation:

• New Equipment necessary ?

• Availibility of new equipment ?

• Range of load control ?

• Risk of fouling and scaling ?

• Cleaning possibilities of new equipment ?

SFGT Gasifier extended by a Radiant Cooler promises

• lowest complexity

• use proven design with full quench and wet gas cleaning

• offers a high efficiency for future IGCC plants ( > 1.5 % )


Energy Sector

SFGT Gasifier with Heat Recovery

Radiant Cooler followed by full quench of raw gasEfficient use of the high temperature heat in the steam generator for HP steam generation High raw gas water content benefits CO-shiftProven reactor and quench design extended by Radiant Cooler

Design features

Efficiency improvement potential:IGCC w/o CO2 capturePlant net efficiency ca. + > 3,5 %(depends upon coal type, water/steam condition, gas turbine)

IGCC with CO2 capturePlant net efficiency ca. + > 1.5 %(depends upon process conditions of CO-shift, coal type, water/steam condition)

Fuel, oxygen, steam

Granulated slag

Cooling screen

Quench water

Heating surface

Pressure vessel

Raw Gas outlet


Energy Sector

University Partner Scope LUAT CFD Modelling

Verification and Validation of Submodels

100 %70 % 105 %1.00

[-] < 0.01

related heatflux

outer wall

inner walls

0.40

[-] < 0.01

related heatflux

•Selection of suitable material for the walls dependingon heat load

•Find an appropriate cleaning system for the wallsdepending on particle load

• Ensure the process parameter

• Sensitive study on water nozzle angles•Selection of suitable material for the walls dependingon heat load

•Find an appropriate cleaning system for the wallsdepending on particle load


Energy Sector

→ Risk and cost reduction of mega coal to chemical plants

→ Where: support of China pioneers mega CTL and CTO technologies

→ Have a possibility to integrate a HRSG in Siemens SFGT Gasifier ifprofitable

→ Maximum product flexibility: chemicals/liquid fuels ↔ electricity

→ Long terme issues: attractive for peak load and energy storage

→ Energy storage by importing renewable power to balance auxiliary power consumption

Conclusion And Siemens SFGT Future Opportunities

Current and future application for coal gasification with polygeneration concepts worldwide with the option to implement a radiant cooler


Energy Sector

Thank you for your attention!

NCPP | Large Coal to Chemical Plant in China

“A Winner Is A Dreamer Who Never Gives Up “

Nelson Mandela


Energy Sector

This document contains forward-looking statements and information – that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”, “plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens’ control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens’ filings with the SEC, which are available on the Siemens website, www.siemens.com and on the SEC’s website, www.sec.gov. Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated.

Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.

Disclaimer

Documents

Development and Engineering of a Synthetic Gas Cooler Concept … · 2018. 4. 17. · 5th International Freiberg Conference on IGCC & XtL Technologies Conference 21. May to 24. May